Pressure charged soft projectile launcher

ABSTRACT

A projectile launcher for launching soft projectiles. The projectile launcher features a breech loading mechanism for loading soft projectiles into the launcher. The projectile launcher includes a pressure vessel which is pressurized by a positive displacement type pump which pumps ambient air into the pressure vessel. The butt stock is integrated to the piston of the pump so that the user may pressurize the pressure vessel by sliding the butt stock back and forth with respect to the pressure vessel. A specialized release valve is provided for optimum release of the pressure charge. Operating pressure for the launcher is limited by the pump design to prevent injury.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the field of soft projectile launching toys. More specifically the present invention comprises a soft projectile launcher with a pressure vessel, an integrated pump for creating a pressure charge, and a specialized trigger-activated release valve for releasing the pressure charge and launching the soft projectile.

2. Description of the Related Art

Projectile launchers have long been known as novelty items. These launchers typically fire potatoes, vegetable slices, marshmallows, tennis balls, and the like. Some are spring loaded, while others use pistons to compress a charge of air. They typically fire a small projectile which can be used in “mock combat” games without actually injuring the target. These devices have also found application other than as novelty items. Some have been used to fire marking projectiles in the veterinary and timber industries. Others have been used as pill injectors for treating horses and cows. Thus, although such projectile launchers are most often viewed as novelty items, their applications may be much broader.

Particularly, in mock combat situations it is desirable to limit the type of projectiles that may be “fired” from a projectile launcher to reduce the risk of injury. One particular concern in the field of novelty projectile launchers is the use of “improvised projectiles.” Users of the launcher often attempt to use the launchers to launch hard projectiles which could cause injury

Accordingly, it would be beneficial to provide a projectile launcher which cannot be used to launch dangerous improvised projectiles and otherwise limits the risk of injury associated with the use of the projectile launcher.

BRIEF SUMMARY OF THE INVENTION

The present invention comprises a projectile launcher for launching soft projectiles. The projectile launcher features a breech loading mechanism for loading soft projectiles into the launcher. The projectile launcher includes a pressure vessel which is pressurized by a positive displacement type pump which pumps ambient air into the pressure vessel. The butt stock is integrated to the piston of the pump so that the user may pressurize the pressure vessel by sliding the butt stock back and forth with respect to the pressure vessel. A specialized release valve is provided for optimum release of the pressure charge. Operating pressure for the launcher is limited by the pump design to prevent injury.

The preferred embodiment of the present invention includes a pressure vessel which is configured to contain a pressure charge of air and a pump which is fluidly connected to the pressure vessel. The preferred embodiment further includes a valve which is configured to contain the pressure charge in the pressure vessel when the valve is in the closed position, and release the pressure charge from the pressure vessel when said valve is in the open position. A bolt which is fluidly connected to the pressure vessel and is configured to receive the pressure charge when the pressure charge is released from the pressure vessel through the valve is also provided. A trigger which is operatively connected to the valve is configured to open the valve to the open position when pulled.

In addition, a barrel may be attached around the bolt such that a portion of the barrel extends outwardly beyond the bolt. A loading chamber is formed within the region of the barrel that extends beyond the bolt. The loading chamber is configured to retain the soft projectile in position in front of the bolt until the user pulls the trigger and releases the pressure charge through the bolt.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a perspective view, showing the present invention

FIG. 2 is an exploded view, showing components of the present invention.

FIG. 3 is a perspective view, showing a pump assembly.

FIG. 4 is a perspective view, showing components of the present invention.

FIG. 5 is a perspective view, showing components of the present invention.

FIG. 6 is a perspective view, illustrating the operation of the present invention.

FIG. 7 is a section view, illustrating the operation of the present invention.

REFERENCE NUMERALS IN THE DRAWINGS

10 projectile launcher 12 butt stock 14 vessel cap 16 pressure vessel 18 trigger grip 20 trigger 22 bolt 24 barrel grip 26 valve 28 neck 30 bolt pin 32 pin tab 34 cutout 36 valve body 38 cylinder 40 pump assembly 42 piston 44 spring 46 dome mating surface 48 valve disk 50 orifice 52 threaded neck 54 trigger 56 square sear 58 protrusion 60 pivot 62 brake 64 brake vents 66 bolt vents 68 barrel neck 70 barrel 72 action slot 74 loading chamber 76 loading port 78 rifled barrel 80 soft projectile 82 spacers 84 air passages 86 mating surface 88 groove

DETAILED DESCRIPTION OF THE INVENTION

The present invention is shown in its assembled state in FIG. 1. Projectile launcher 10 includes butt stock 12 which inserts through vessel cap 14 into pressure vessel 16. Pressure vessel 16 is attached to bolt 22 so that the two components are fluidly connected, and trigger grip 18 is attached around the connection between pressure vessel 16 and bolt 22. Trigger 20 is provided for releasing a pressure charge from pressure vessel 16 through bolt 22 as will be described subsequently. Connected to barrel grip 24 is the barrel of the projectile launcher. The barrel is attached around bolt 22 so that it can freely rotate around bolt 22. Bolt pin 30 (FIG. 2) is provided to restrict the movement of the barrel with respect to bolt 22, however, to an “L” shaped path as will be described subsequently.

FIG. 2 shows pump assembly 40 removed from pressure vessel 16. In the assembled state, pump cylinder 18 is trapped inside pressure vessel 16 by vessel cap 14. Valve 26, a one-way valve, is at the end of pump cylinder 18 opposite butt stock 12. Butt stock 12 is attached to piston 16 which slides back and forth within pump cylinder 18. Vessel cap 14 may be removably attached to pressure vessel 16 by female threading on the inside of vessel cap 14 and male threading on the outside of neck 28 of pressure vessel 16.

Pump assembly 40 is shown in greater detail in FIG. 3. Pump assembly 40 is generally a positive displacement pump. Air enters cylinder 38 through a one-way valve on the side of cylinder 38 near butt stock 12. The user manipulates butt stock 12 in a back and forth motion causing piston 42 to travel back and forth within cylinder 38. When butt stock 12 is drawn all the way to a fully-open intake position, ambient air enters cylinder 38 through the one-way valve. When butt stock 12 is pressed completely forward, such as shown in FIG. 3, air within cylinder 38 is compressed and expelled through valve 26. As mentioned previously, valve 26 is also a one-way valve. Accordingly, the pressure charge that is developed in pressure vessel 16 will not escape through pump assembly 40.

Operating pressure for the launcher is limited by the design of pump assembly 40. V_(B) represents the total volume of cylinder 38 when the plunger is at full backstroke, or at the fully-open intake position. When the user pushes butt stock 12 into cylinder 38, V_(A) represents the total volume of cylinder 38 when piston 42 is pushed as far as possible. At full backstroke, the air in cylinder 38 is at atmospheric pressure. At full forward stroke, or at the fully-compressed compression position, the air in pump housing 38 is V_(B)/V_(A) times atmospheric pressure. This of course assumes that air does not escape through valve 26 into pressure vessel 16. When pressure inside pressure vessel 16 is equal to the pressure in cylinder 38 when piston 42 is pushed all the away in, this assumption holds true. As an example, if V_(B) is twice the size as V_(A), then pressure vessel 16 can only be pressurized to two times atmospheric pressure. This feature helps prevent injury caused by projectiles launched at dangerous velocities.

Pressure vessel 16 is sealed on the side opposite pump assembly 40 by a valve which is captured between pressure vessel 16 and bolt 22 as shown in FIG. 4. The valve includes valve disk 48 and valve body 36. Valve disk 48 is preferably made of a flexible material such as rubber, silicone, plastic, or other polymer. Valve disk 48 is substantially annular in shape, having a perimeter and a center bore. Valve disk 48 may be situated within orifice 50 of bolt 22 so that the perimeter of valve disk 48 mates with mating surface 86 of bolt 22 when threaded neck 52 of pressure vessel is threadedly engaged with orifice 50 of bolt 22. Groove 88 may be optionally provided in mating surface 66 along with a corresponding annular rib on valve disk 48 to ensure alignment and an air-tight seal.

Bolt 22, valve disk 48, pressure vessel 16, and pump assembly 40 are substantially aligned along a central axis. Bolt pin 30 extends across the interior of bolt 22 transversely to the central axis. Bolt pin 30 is held in place by a pair of pin tabs 32 which project through the outside surface of bolt 22. Pin tabs 32 serve another function which will be described subsequently. Cutout 34 is provided where the central axis intersects bolt pin 30. Cutout 34 holds valve body 36 in alignment with valve disk 48 and allows valve body 36 to travel towards and away from valve disk 48. Valve body 36 includes dome mating surface 48 which mates with valve disk 48 and prevents air from escaping through the center bore. Spring 44 is provided to bias valve body 36 against valve disk 48.

When the valve is in the closed position, square sear 56 mates with the back surface of dome mating surface 46 and prevents valve body 36 from opening as the pressure in pressure vessel 16 exceeds the force exerted by spring 44. Trigger 54 is attached to trigger grip 18 by pivot 60. Trigger 54 has protrusion 58 which attaches trigger 54 to square sear 56. When the user pulls trigger 54, trigger 54 rotates about pivot 60 causing square sear 56 to pull away from the back side of dome mating surface 46. If pressure vessel 16 has sufficient pressure to overcome the force of spring 44, the valve will open, and the pressure charge will rapidly expel through valve disk 48 into bolt 22.

A perspective view of a section of bolt 22 is provided in FIG. 5. Dome mating surface 46 projects upwardly to an apex. In the preferred embodiment, dome mating surface 46 has a convex curvature facing valve disk 48. This geometry cause valve disk 48 to mate more tightly with dome mating surface 46 as pressure in pressure vessel 16 increases. Spacers 82 are provided around dome mating surface 46 to ensure alignment. Air passages 84 are formed between spacers 82. Air passages 84 and the convex shape of dome mating surface 46 allow the pressure charge to pass around valve body 36 abruptly when the valve opens. The reader will appreciate that whenever the valve is in the closed position, air passages 84 are covered by valve disk 48. When square sear 56 is pulled away, however, the pressure charge pushes against dome mating surface 46, causing valve body 36 to compress spring 44. This exposes air passages 84 to the pressure charge, and the pressure charge rapidly passes around valve body 36. This abrupt release of the pressure charge is desirable in order for the soft projectile to shoot out of the projectile launcher with maximum force.

The valve assembly described previously offers many unique advantages over conventional valves. The valve resets with very little force compared to the pressure limit of the valve. One stroke of the pump reliably forms the seal between valve disk 48 and dome mating surface 46. Also, the full flow rate resulting from the release of the pressure charge is achieved almost instantly and is measurably faster than the flow rates achievable with a ball valve or gate valve.

The loading feature for the present invention is shown in greater detail in FIG. 6. Barrel 70 is attached around bolt 22 so that it may rotate around the central axis of bolt 22. Barrel 70 may also travel axially with respect to the central axis of bolt 22. Pin tab 32 is provided, however, to limit the movement of barrel 70 with respect to bolt 22. A pair of action slots 72 are provided on opposite sides of barrel 70. Pin tab 32 acts as a guide and restricts the movement of barrel 70 to an L-shaped path with respect to bolt 22. Barrel grip 24 is provided to assist the user in manipulating barrel 70.

The sidewalls of action slots 72, defined as the surfaces on barrel 70 which are substantially perpendicular to bolt 22, may be angled inward (so that the slot is wider on the surface facing bolt 22 than on the outward facing surface of barrel 70) to create a better plastic on plastic seal between bolt 22 and barrel 70. An angle of approximately 2 degrees or greater is particularly effective.

To load a soft projectile in the projectile launcher, barrel 70 is rotated a quarter of a turn with respect to bolt 22 and advanced forward axially along bolt 22 until the loading port passes over the end of bolt 22, exposing the hollow interior of barrel 70 (or loading chamber 74) as shown in FIG. 6. Bolt vents 66 are provided on the end of bolt 22. Bolt vents 66 allow the pressure charge to pass through bolt 22 into barrel 70 when the pressure charge is released. A soft projectile, such as a marshmallow, may then be loaded into loading chamber 74. Before pulling the trigger and releasing the pressure charge, the user reverses barrel 70 axially along bolt 22 and then rotates barrel 70 back to its starting position.

Barrel 70 may be divided into two principal portions when barrel 70 is in the loaded and ready to fire position, as shown in FIG. 7. One portion wraps around and mates with the exterior surface of bolt 22. Action slot 72 and loading port 76 lie in this portion of the barrel. When barrel 70 is in the presently illustrated position, action slot 72 and loading port 76 are sealed off from the interior of barrel 70 by bolt 22. In the preferred embodiment, bolt 22 and barrel 70 are both made of plastic. A plastic-on-plastic seal is created between bolt 22 and barrel 70 when the components are in the loaded position.

The second portion of barrel 70 extends beyond the end of bolt 22. This portion of barrel 70 acts as the muzzle for the projectile launcher. Barrel neck 68 is provided in the interior of the muzzle to compress soft projectile 80 and direct soft projectile 80 through rifled barrel 78 as the pressure charge passes through bolt vents 66 and forces soft projectile 80 out of the projectile launcher. Barrel neck 68 defines the tapered region of barrel 70 between bolt 22 and rifled barrel 78. The muzzle is rifled to prevent the use of improvised hard projectiles. A hexagonal shaped cross-section is preferred for rifled barrel 78, although other polygonal shaped cross-sections may also be used. In the preferred embodiment, the hexagonal rifling forms a hexagonal helical pattern as the hexagonally-shaped cross section rotates angularly along the length of the barrel as illustrated in FIG. 7. Unless a hard object has the shape of a hexagonal prism and is within a small tolerance of being the same size of the interior of rifled barrel 78, the hard object will not launch out of the projectile launcher with very much energy. The object will either get stuck in rifled barrel 78 or most of the air from the pressure charge will divert around the object. Soft projectiles will deform to fit through rifled barrel 78, however, and create an air tight seal when doing so.

Muzzle brake 62 is another safety feature of the present invention. Muzzle brake 62 extends beyond rifled barrel 78 and has a plurality of brake vents 64. This feature prevents the user from placing their mouth around the muzzle of the projectile launcher and inhaling the soft projectile or discharging a pressure charge into the user's lungs. Brake vents 64 prevent the user from creating suction on the muzzle. If the user inhales through the end of muzzle brake 62, air will simply filter through brake vents 64. If the user puts the muzzle in a person's mouth, the pressure charge will be diverted through brake vents 64 and will not be forced into the person's lungs.

With the components of projectile launcher 10 now described, the user will appreciate how the launcher is used. The user rotates and slides forward barrel 70, places a soft projectile in loading chamber 74 in front of bolt 22, and then slides back and rotates barrel 70 to seal loading port 76. The user then pumps pump assembly 40 repeatedly until the desired pressure charge is created within pressure vessel 16. The user then pulls trigger 54 to release the pressure charge into bolt 22 which launches the projectile. The user may also create the desired pressure charge within pressure vessel 16 first before loading the projectile into loading chamber 74.

The preceding description contains significant detail regarding the novel aspects of the present invention. It should not be construed, however, as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. As an example, many different types of pumps may be used to create the pressure charge. Such variations would not alter the function of the invention. Thus, the scope of the invention should be fixed by the following claims, rather than by the examples given. 

1. A projectile launcher for shooting a soft projectile comprising: a. a pressure vessel, said pressure vessel configured to contain a pressure charge of air, said pressure charge of air having a pressure greater relative pressure than air outside of said pressure vessel; b. a pump, said pump fluidly connected to said pressure vessel and configured to produce said pressure charge when said pump is operated; c. a valve, having a valve disk, said valve positionable in an open position and a closed position, said valve configured to contain said pressure charge in said pressure vessel when said valve is in said closed position, and release said pressure charge from said pressure vessel when said valve is in said open position, said valve biased so that said valve is normally retained in said closed position; d. a bolt, said bolt fluidly connected to said pressure vessel and configured to receive said pressure charge when said pressure charge is released from said pressure vessel through said valve; e. a trigger, said trigger operatively connected to said valve and configured to open said valve to said open position when pulled; and f. wherein said valve disk is captured between said pressure vessel and said bolt.
 2. The projectile launcher of claim 1, wherein said pump is partially situated within said pressure vessel so that said pump is at least partially encapsulated by said pressure vessel.
 3. The projectile launcher of claim 1, wherein said pump includes a. a cylinder, having an interior, a first end, a second end, and a length therebetween; b. a second valve, said second valve proximal to said first end of said cylinder, said valve configured to allow air to pass from said interior of said cylinder to said pressure vessel, but restricts air from passing from said pressure vessel to said interior of said cylinder; c. a piston, having a first end and a second end, said piston situated in said cylinder, said piston configured to travel back and forth across said length of said cylinder between a fully-open intake position wherein said piston is at a first location distal said second valve and a fully-compressed compression position wherein said piston is at a second location proximal said second valve; d. wherein air enters said interior of said cylinder distal said second valve; e. wherein a first volume is defined by the volume within said cylinder between said first end of said piston and said second valve when said piston is at said first location, and a second volume is defined by the volume within said cylinder between said first end of said piston and said second valve when said piston is at said second location; and f. wherein the maximum operating pressure of said projectile launcher is limited by a ratio of said first volume to said second volume.
 4. The projectile launcher of claim 3, said pump further comprising a butt stock attached to said piston proximal said second end of said piston and projecting outside said pump.
 5. The projectile launcher of claim 1, further comprising: a. a barrel attached around said bolt and projecting outward axially therefrom, said barrel divided into a bolt portion where said barrel wraps around said bolt and a muzzle portion where said barrel extends beyond said bolt, said barrel having a hollow interior and a substantially cylindrical exterior; b. a loading chamber within said hollow interior of said barrel, said loading chamber configured to retain said soft projectile in position in front of said bolt; and c. a loading port in said bolt portion of said barrel, said loading port adapted for loading said soft projectile such that said soft projectile may be inserted through said loading port and received in said loading chamber.
 6. The projectile launcher of claim 5, wherein said soft projectile is loaded into said projectile launcher by sliding said barrel axially along said bolt so that said loading port extends beyond said bolt exposing said hollow interior of said barrel through said loading port, inserting said soft projectile through said loading port so that it is received within said hollow interior of said barrel, and sliding said barrel axially along said bolt so that said loading port is situated over said bolt.
 7. The projectile launcher of claim 1, said valve comprising: a. a flexible valve disk, said valve disk having a perimeter, a center bore, and a flexible material therebetween; and b. a valve body, said valve body having a domed surface configured to mate with said flexible valve disk.
 8. The projectile launcher of claim 7, said valve further comprising air passages in said domed surface.
 9. The projectile launcher of claim 8, said valve moveable between said open position and said closed position, wherein a. whenever said valve is in said closed position, said air passages are covered by said flexible material such that air may not pass from a first side of said valve to a second side of said valve; and b. whenever said valve is in said open position, said air passages are exposed and such that air may pass from said first side of said valve to said second side of said valve.
 10. The projectile launcher of claim 1, further comprising a barrel attached around said bolt and projecting outward axially therefrom, said barrel having a first end proximal said bolt and a second end distal said bolt, and a hollow interior.
 11. The projectile launcher of claim 10, further comprising a muzzle brake proximal said second end of said barrel, said muzzle brake having a hollow interior aligned with said hollow interior of said barrel, an exterior surface, and a plurality of vents in said exterior surface permitting air to pass therethrough.
 12. The projectile launcher of claim 10, said barrel comprising rifling proximal said second end wherein said rifling is configured to prevent the passage of improvised hard projectiles therethrough.
 13. The projectile launcher of claim 12, said barrel comprising hexagonal rifling.
 14. A projectile launcher for shooting a soft projectile comprising; a. a pressure vessel, said pressure vessel configured to contain a pressure charge of air, said pressure charge of air having a pressure greater relative pressure than air outside of said pressure vessel; b. a pump, said pump fluidly connected to said pressure vessel and configured to produce said pressure charge when said pump is operated; c. a valve, having an open position and a closed position, said valve configured to contain said pressure charge in said pressure vessel when said valve is in said closed position, and release said pressure charge from said pressure vessel when said valve is in said open position, said valve biased so that said valve is normally retained in said closed position; d. a bolt, said bolt fluidly connected to said pressure vessel and configured to receive said pressure charge when said pressure charge is released from said pressure vessel through said valve; e. a trigger, said trigger operatively connected to said valve and configured to open said valve to said open position when pulled; f. a barrel attached around said bolt and projecting outward axially therefrom, said barrel divided into a bolt portion where said barrel wraps around said bolt and a muzzle portion where said barrel extends beyond said bolt, said barrel having a hollow interior and a substantially cylindrical exterior; g. a loading chamber within said hollow interior of said barrel, said loading chamber configured to retain said soft projectile in position in front of said bolt; and h. a loading port in said bolt portion of said barrel, said loading port adapted for loading said soft projectile such that said soft projectile may be inserted through said loading port and received in said loading chamber.
 15. The projectile launcher of claim 14, wherein said soft projectile is loaded into said projectile launcher by: a. sliding said barrel axially along said bolt so that said loading port extends beyond said bolt, thereby exposing said hollow interior of said barrel through said loading port; b. inserting said soft projectile through said loading port so that it is received within said hollow interior of said barrel; and c. sliding said barrel axially along said bolt so that said loading port is situated over said bolt.
 16. The projectile launcher of claim 14, said barrel further comprising a first end proximal said bolt, a second end distal said bolt, a hollow interior, and a muzzle brake proximal said second end of said barrel, said muzzle brake having a hollow interior aligned with said hollow interior of said barrel, an exterior surface, and a plurality of vents in said exterior surface permitting air to pass therethrough.
 17. The projectile launcher of claim 14, said valve comprising: a. a flexible valve disk, said valve disk having a perimeter, a center bore, and a flexible material therebetween; and b. a valve body, said valve body having a domed surface configured to mate with said flexible valve disk.
 18. A projectile launcher for shooting a soft projectile comprising: a. a pressure vessel, said pressure vessel configured to contain a pressure charge of air, said pressure charge of air having a pressure greater relative pressure than air outside of said pressure vessel; b. a pump, said pump fluidly connected to said pressure vessel and configured to produce said pressure charge when said pump is operated; c. a valve, having a valve disk, an open position and a closed position, said valve configured to contain said pressure charge in said pressure vessel when said valve is in said closed position, and release said pressure charge from said pressure vessel when said valve is in said open position, said valve biased so that said valve is normally retained in said closed position; d. a bolt, said bolt fluidly connected to said pressure vessel and configured to receive said pressure charge when said pressure charge is released from said pressure vessel through said valve; e. a trigger, said trigger operatively connected to said valve and configured to open said valve to said open position when pulled; and f. a barrel attached around said bolt and projecting outward axially therefrom, said barrel having a first end proximal said bolt, a second end distal said bolt, a hollow interior, and a muzzle brake proximal said second end of said barrel, said muzzle brake having a hollow interior aligned with said hollow interior of said barrel, an exterior surface, and a plurality of vents in said exterior surface permitting air to pass therethrough.
 19. The projectile launcher of claim 18, said valve comprising: a. a flexible valve disk, said valve disk having a perimeter, a center bore, and a flexible material therebetween; and b. a valve body, said valve body having a domed surface configured to mate with said flexible valve disk.
 20. The projectile launcher of claim 19, said valve further comprising air passages in said domed surface. 